Method and system of modifying a liquid level during start-up operations

ABSTRACT

The present disclosure provides a method for separating a feed stream in a distillation tower. The method includes operating a controlled freeze zone section in a distillation tower that separates a feed stream at a temperature and pressure at which the feed stream forms a solid in the controlled freeze zone section, wherein the feed stream includes a first contaminant; maintaining a melt tray assembly in the controlled freeze zone section; introducing the feed stream to the controlled freeze zone section; and accumulating a liquid in the melt tray assembly until the liquid is at a predetermined liquid level in the controlled freeze zone section, by: feeding a second contaminant to the controlled freeze zone section; and adding the second contaminant to the melt tray assembly, wherein the liquid comprises the second contaminant.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the priority benefit of both U.S. Provisional patent application No. 61/912,984 on Dec. 6, 2013 entitled METHOD AND SYSTEM OF MODIFYING A LIQUID LEVEL DURING START-UP OPERATIONS; the entirety of which is incorporated by reference herein.

This application is related to but does not claim priority to U.S. Provisional patent application Nos. 61/912,957 filed on Dec. 6, 2013 entitled METHOD AND DEVICE FOR SEPARATING HYDROCARBONS AND CONTAMINANTS WITH A SPRAY ASSEMBLY; 62/044,770 filed on Sep. 2, 2014 entitled METHOD AND DEVICE FOR SEPARATING HYDROCARBONS AND CONTAMINANTS WITH A SPRAY ASSEMBLY; 61/912,959 filed on Dec. 6, 2013 entitled METHOD AND SYSTEM OF MAINTAINING A LIQUID LEVEL IN A DISTILLATION TOWER; 61/912,964 filed on Dec. 6, 2013 entitled METHOD AND DEVICE FOR SEPARATING A FEED STREAM USING RADIATION DETECTORS; 61/912,970 filed on Dec. 6, 2013 entitled METHOD AND SYSTEM OF DEHYDRATING A FEED STREAM PROCESSED IN A DISTILLATION TOWER; 61/912,975 filed on Dec. 6, 2013 entitled METHOD AND SYSTEM FOR SEPARATING A FEED STREAM WITH A FEED STREAM DISTRIBUTION MECHANISM; 61/912,978 filed on Dec. 6, 2013 entitled METHOD AND SYSTEM FOR PREVENTING ACCUMULATION OF SOLIDS IN A DISTILLATION TOWER; 61/912,983 filed on Dec. 6, 2013 entitled METHOD OF REMOVING SOLIDS BY MODIFYING A LIQUID LEVEL IN A DISTILLATION TOWER; 61/912,986 filed on Dec. 6, 2013 entitled METHOD AND DEVICE FOR SEPARATING HYDROCARBONS AND CONTAMINANTS WITH A HEATING MECHANISM TO DESTABILIZE AND/OR PREVENT ADHESION OF SOLIDS; 61/912,987 filed on Dec. 6, 2013 entitled METHOD AND DEVICE FOR SEPARATING HYDROCARBONS AND CONTAMINANTS WITH A SURFACE TREATMENT MECHANISM.

BACKGROUND

Fields of Disclosure

The disclosure relates generally to the field of fluid separation. More specifically, the disclosure relates to the cryogenic separation of contaminants, such as acid gas, from a hydrocarbon.

Description of Related Art

This section is intended to introduce various aspects of the art, which may be associated with the present disclosure. This discussion is intended to provide a framework to facilitate a better understanding of particular aspects of the present disclosure. Accordingly, it should be understood that this section should be read in this light, and not necessarily as admissions of prior art.

The production of natural gas hydrocarbons, such as methane and ethane, from a reservoir oftentimes carries with it the incidental production of non-hydrocarbon gases. Such gases include contaminants, such as at least one of carbon dioxide (“CO₂”), hydrogen sulfide (“H₂S”), carbonyl sulfide, carbon disulfide and various mercaptans. When a feed stream being produced from a reservoir includes these contaminants mixed with hydrocarbons, the stream is oftentimes referred to as “sour gas.”

Many natural gas reservoirs have relatively low percentages of hydrocarbons and relatively high percentages of contaminants. Contaminants may act as a diluent and lower the heat content of hydrocarbons. Some contaminants, like sulfur-bearing compounds, are noxious and may even be lethal. Additionally, in the presence of water some contaminants can become quite corrosive.

It is desirable to remove contaminants from a stream containing hydrocarbons to produce sweet and concentrated hydrocarbons. Specifications for pipeline quality natural gas typically call for a maximum of 2-4% CO₂ and ¼ grain H₂S per 100 scf (4 ppmv) or 5 mg/Nm3 H₂S. Specifications for lower temperature processes such as natural gas liquefaction plants or nitrogen rejection units typically require less than 50 ppm CO₂.

The separation of contaminants from hydrocarbons is difficult and consequently significant work has been applied to the development of hydrocarbon/contaminant separation methods. These methods can be placed into three general classes: absorption by solvents (physical, chemical and hybrids), adsorption by solids, and distillation.

Separation by distillation of some mixtures can be relatively simple and, as such, is widely used in the natural gas industry. However, distillation of mixtures of natural gas hydrocarbons, primarily methane, and one of the most common contaminants in natural gas, carbon dioxide, can present significant difficulties. Conventional distillation principles and conventional distillation equipment are predicated on the presence of only vapor and liquid phases throughout the distillation tower. The separation of CO₂ from methane by distillation involves temperature and pressure conditions that result in solidification of CO₂ if a pipeline or better quality hydrocarbon product is desired. The required temperatures are cold temperatures typically referred to as cryogenic temperatures.

Certain cryogenic distillations can overcome the above mentioned difficulties. These cryogenic distillations provide the appropriate mechanism to handle the formation and subsequent melting of solids during the separation of solid-forming contaminants from hydrocarbons. The formation of solid contaminants in equilibrium with vapor-liquid mixtures of hydrocarbons and contaminants at particular conditions of temperature and pressure takes place in a controlled freeze zone section.

The solids formed in the controlled freeze zone section may be melted in a melt tray assembly of the controlled freeze zone liquid. Liquid in the melt tray assembly helps melt the solids.

Solids, however, may accumulate in the controlled freeze zone section when the melt tray assembly does not contain a sufficient amount of liquid to melt the solids. The melt tray assembly may not contain a sufficient amount of liquid during start-up of the distillation tower. The liquid originates from the feed stream processed in the distillation tower. The melt-tray assembly may not accumulate enough liquid during start-up if the feed stream introduced into the distillation tower does not include enough contaminants. This feed stream may not include enough contaminants if the feed stream comprises less than 20% contaminants.

The accumulation of solids is disadvantageous. The accumulation can interference with the proper operation of and the effective separation of methane from contaminants.

A need, therefore, exists for improved technology for increasing the amount of liquid in the melt tray assembly during start-up of the distillation tower.

SUMMARY

The present disclosure provides a device and method for separating contaminants from hydrocarbons, among other things.

A method for separating a feed stream in a distillation tower may comprise operating a controlled freeze zone section in a distillation tower that separates a feed stream at a temperature and pressure at which the feed stream forms a solid in the controlled freeze zone section, wherein the feed stream includes a first contaminant; maintaining a melt tray assembly in the controlled freeze zone section; introducing the feed stream to the controlled freeze zone section; and accumulating a liquid in the melt tray assembly until the liquid is at a predetermined liquid level in the controlled freeze zone section, by: feeding a second contaminant to the controlled freeze zone section; and adding the second contaminant to the melt tray assembly, wherein the liquid comprises the second contaminant.

A method for producing hydrocarbons in a distillation tower may comprise operating a controlled freeze zone section in a distillation tower that separates the feed stream at a temperature and pressure at which the feed stream forms a solid in the controlled freeze zone section, wherein the feed stream includes a first contaminant and a hydrocarbon; maintaining a melt tray assembly in the controlled freeze zone section; introducing the feed stream to the controlled freeze zone section; accumulating a liquid in the melt tray assembly until the liquid is at a predetermined liquid level in the controlled freeze zone section, by: feeding a second contaminant to the controlled freeze zone section; and adding the second contaminant to the melt tray assembly, wherein the liquid comprises the second contaminant; and; producing the hydrocarbon after recovering the hydrocarbon.

A system for separating a first contaminant in a feed stream from a hydrocarbon in the feed stream may comprise a distillation tower comprising a controlled freeze zone section constructed and arranged to separate the feed stream at a temperature and pressure at which the feed stream forms a solid, wherein the controlled freeze section includes a melt tray assembly having a liquid that melts the solid, and wherein the liquid comprises a first contaminant in the feed stream; an inlet channel extending to the controlled freeze zone section; and at least one of: a first storage unit holding a second contaminant; and a first channel extending from the first storage unit to the controlled freeze zone section; and an indirect channel that extends from at least one of (i) the distillation tower to the inlet channel (ii) the distillation tower to the first channel and (iii) a second storage unit to the inlet channel, wherein the second storage unit holds the second contaminant.

The foregoing has broadly outlined the features of the present disclosure in order that the detailed description that follows may be better understood. Additional features will also be described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects and advantages of the disclosure will become apparent from the following description, appending claims and the accompanying drawings, which are briefly described below.

FIG. 1 is a schematic diagram of a tower with sections within a single vessel.

FIG. 2 is a schematic diagram of a tower with sections within multiple vessels.

FIG. 3 is a schematic diagram of a tower with sections within a single vessel.

FIG. 4 is a schematic diagram of a tower with sections within multiple vessels.

FIG. 5 is a schematic diagram of a controlled freeze zone section and a lower section of a distillation tower.

FIG. 6 is a flowchart of a method within the scope of the present disclosure.

It should be noted that the figures are merely examples and no limitations on the scope of the present disclosure are intended thereby. Further, the figures are generally not drawn to scale, but are drafted for purposes of convenience and clarity in illustrating various aspects of the disclosure.

DETAILED DESCRIPTION

For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the features illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Any alterations and further modifications, and any further applications of the principles of the disclosure as described herein are contemplated as would normally occur to one skilled in the art to which the disclosure relates. It will be apparent to those skilled in the relevant art that some features that are not relevant to the present disclosure may not be shown in the drawings for the sake of clarity.

As referenced in this application, the terms “stream,” “gas stream,” “vapor stream,” and “liquid stream” refer to different stages of a feed stream as the feed stream is processed in a distillation tower that separates methane, the primary hydrocarbon in natural gas, from contaminants. Although the phrases “gas stream,” “vapor stream,” and “liquid stream,” refer to situations where a gas, vapor, and liquid is mainly present in the stream, respectively, there may be other phases also present within the stream. For example, a gas may also be present in a “liquid stream.” In some instances, the terms “gas stream” and “vapor stream” may be used interchangeably.

The disclosure relates to a system and method for separating a feed stream in a distillation tower that ensures that enough liquid accumulates in a melt-tray assembly during start-up of the distillation tower to help prevent the accumulation of solids in the distillation tower. FIGS. 1-6 of the disclosure display various aspects of the system and method.

The system and method may separate a feed stream having methane and contaminants. The system may comprise a distillation tower 104, 204 (FIGS. 1-2). The distillation tower 104, 204 may separate the contaminants from the methane.

The distillation tower 104, 204 may be separated into three functional sections: a lower section 106, a middle controlled freeze zone section 108 and an upper section 110. The distillation tower 104, 204 may incorporate three functional sections when the upper section 110 is needed and/or desired.

The distillation tower 104, 204 may incorporate only two functional sections when the upper section 110 is not needed and/or desired. When the distillation tower does not include an upper section 110, a portion of vapor leaving the middle controlled freeze zone section 108 may be condensed in a condenser 122 and returned as a liquid stream via a spray assembly 129. Moreover, lines 18 and 20 may be eliminated, elements 124 and 126 may be one and the same, and elements 150 and 128 may be one and the same. The stream in line 14, now taking the vapors leaving the middle controlled freeze section 108, directs these vapors to the condenser 122.

The lower section 106 may also be referred to as a stripper section. The middle controlled freeze zone section 108 may also be referred to as a controlled freeze zone section. The upper section 110 may also be referred to as a rectifier section.

The sections of the distillation tower 104 may be housed within a single vessel (FIGS. 1 and 3). For example, the lower section 106, the middle controlled freeze zone section 108, and the upper section 110 may be housed within a single vessel 164.

The sections of the distillation tower 204 may be housed within a plurality of vessels to form a split-tower configuration (FIGS. 2 and 4). Each of the vessels may be separate from the other vessels. Piping and/or another suitable mechanism may connect one vessel to another vessel. In this instance, the lower section 106, middle controlled freeze zone section 108 and upper section 110 may be housed within two or more vessels. For example, as shown in FIGS. 2 and 4, the upper section 110 may be housed within a single vessel 254 and the lower and middle controlled freeze zone sections 106, 108 may be housed within a single vessel 264. When this is the case, a liquid stream exiting the upper section 110, may exit through a liquid outlet bottom 260. The liquid outlet bottom 260 is at the bottom of the upper section 110. Although not shown, each of the sections may be housed within its own separate vessel, or one or more section may be housed within separate vessels, or the upper and middle controlled freeze zone sections may be housed within a single vessel and the lower section may be housed within a single vessel, etc. When sections of the distillation tower are housed within vessels, the vessels may be side-by-side along a horizontal line and/or above each other along a vertical line.

The split-tower configuration may be beneficial in situations where the height of the distillation tower, motion considerations, and/or transportation issues, such as for remote locations, need to be considered. This split-tower configuration allows for the independent operation of one or more sections. For example, when the upper section is housed within a single vessel and the lower and middle controlled freeze zone sections are housed within a single vessel, independent generation of reflux liquids using a substantially contaminant-free, largely hydrocarbon stream from a packed gas pipeline or an adjacent hydrocarbon line, may occur in the upper section. And the reflux may be used to cool the upper section, establish an appropriate temperature profile in the upper section, and/or build up liquid inventory at the bottom of the upper section to serve as an initial source of spray liquids for the middle controlled freeze zone section. Moreover, the middle controlled freeze zone and lower sections may be independently prepared by chilling the feed stream, feeding it to the optimal location be that in the lower section or in the middle controlled freeze zone section, generating liquids for the lower and the middle controlled freeze zone sections, and disposing the vapors off the middle controlled freeze zone section while they are off specification with too high a contaminant content. Also, liquid from the upper section may be intermittently or continuously sprayed, building up liquid level in the bottom of the middle controlled freeze zone section and bringing the contaminant content in the middle controlled freeze zone section down and near steady state level so that the two vessels may be connected to send the vapor stream from the middle controlled freeze zone section to the upper section, continuously spraying liquid from the bottom of the upper section into the middle controlled freeze zone section and stabilizing operations into steady state conditions. The split tower configuration may utilize a sump of the upper section as a liquid receiver for the pump 128, therefore obviating the need for a liquid receiver 126 in FIGS. 1 and 3.

The system may also include a heat exchanger 100 (FIGS. 1-4). The feed stream 10 may enter the heat exchanger 100 before entering the distillation tower 104, 204. The feed stream 10 may be cooled within the heat exchanger 100. The heat exchanger 100 helps drop the temperature of the feed stream 10 to a level suitable for introduction into the distillation tower 104, 204.

The system may include an expander device 102 (FIGS. 1-4). The feed stream 10 may enter the expander device 102 before entering the distillation tower 104, 204. The feed stream 10 may be expanded in the expander device 102 after exiting the heat exchanger 100. The expander device 102 helps drop the temperature of the feed stream 10 to a level suitable for introduction into the distillation tower 104, 204. The expander device 102 may be any suitable device, such as a valve. If the expander device 102 is a valve, the valve may be any suitable valve that may aid in cooling the feed stream 10 before it enters the distillation tower 104, 204. For example, the valve 102 may comprise a Joule-Thompson (J-T) valve.

The system may include a feed separator 103 (FIGS. 3-4). The feed stream may enter the feed separator before entering the distillation tower 104, 204. The feed separator may separate a feed stream having a mixed liquid and vapor stream into a liquid stream and a vapor stream. Lines 12 may extend from the feed separator to the distillation tower 104, 204. One of the lines 12 may receive the vapor stream from the feed separator. Another one of the lines 12 may receive the liquid stream from the feed separator. Each of the lines 12 may extend to the same and/or different sections (i.e. middle controlled freeze zone, and lower sections) of the distillation tower 104, 204. The expander device 102 may or may not be downstream of the feed separator 103. The expander device 102 may comprise a plurality of expander devices 102 such that each line 12 has an expander device 102.

The system may include a dehydration unit 261 (FIGS. 1-4). The feed stream 10 may enter the dehydration unit 261 before entering the distillation tower 104, 204. The feed stream 10 enters the dehydration unit 261 before entering the heat exchanger 100 and/or the expander device 102. The dehydration unit 261 removes water from the feed stream 10 to prevent water from later presenting a problem in the heat exchanger 100, expander device 102, feed separator 103, or distillation tower 104, 204. The water can present a problem by forming a separate water phase (i.e., ice and/or hydrate) that plugs lines, equipment or negatively affects the distillation process. The dehydration unit 261 dehydrates the feed stream to a dew point sufficiently low to ensure a separate water phase does not form at any point downstream during the rest of the process. The dehydration unit may be any suitable dehydration mechanism, such as a molecular sieve or a glycol dehydration unit.

The system may include a filtering unit (not shown). The feed stream 10 may enter the filtering unit before entering the distillation tower 104, 204. The filtering unit may remove undesirable contaminants from the feed stream before the feed stream enters the distillation tower 104, 204. Depending on what contaminants are to be removed, the filtering unit may be before or after the dehydration unit 261 and/or before or after the heat exchanger 100.

The system may include a line 12 (FIGS. 1-4). The line may also be referred to as an inlet channel 12. The feed stream 10 may be introduced into the distillation tower 104, 204 through the line 12. The line 12 may extend to the lower section 106 or the middle controlled freeze zone section 108 of the distillation tower 104, 204. For example, the line 12 may extend to the lower section 106 such that the feed stream 10 may enter the lower section 106 of the distillation tower 104, 204 (FIGS. 1-4). The line 12 may directly or indirectly extend to the lower section 106 or the middle controlled freeze zone section 108. The line 12 may extend to an outer surface of the distillation tower 104, 204 before entering the distillation tower.

If the system includes the feed separator 103 (FIGS. 3-4), the line 12 may comprise a plurality of lines 12. Each line may be the same line as one of the lines that extends from the feed separator to a specific portion of the distillation tower 104, 204.

The lower section 106 is constructed and arranged to separate the feed stream 10 into an enriched contaminant bottom liquid stream (i.e., liquid stream) and a freezing zone vapor stream (i.e., vapor stream). The lower section 106 separates the feed stream at a temperature and pressure at which no solids form. The liquid stream may comprise a greater quantity of contaminants than of methane. The vapor stream may comprise a greater quantity of methane than of contaminants. In any case, the vapor stream is lighter than the liquid stream. As a result, the vapor stream rises from the lower section 106 and the liquid stream falls to the bottom of the lower section 106.

The lower section 106 may include and/or connect to equipment that separates the feed stream. The equipment may comprise any suitable equipment for separating methane from contaminants, such as one or more packed sections 181, or one or more distillation trays with perforations downcomers and weirs (FIGS. 1-4).

The equipment may include components that apply heat to the stream to form the vapor stream and the liquid stream. For example, the equipment may comprise a first reboiler 112 that applies heat to the stream. The first reboiler 112 may be located outside of the distillation tower 104, 204. The equipment may also comprise a second reboiler 172 that applies heat to the stream. The second reboiler 172 may be located outside of the distillation tower 104, 204. Line 117 may lead from the distillation tower to the second reboiler 172. Line 17 may lead from the second reboiler 172 to the distillation tower. Additional reboilers, set up similarly to the second reboiler described above, may also be used.

The first reboiler 112 may apply heat to the liquid stream that exits the lower section 106 through a liquid outlet 160 of the lower section 106. The liquid stream may travel from the liquid outlet 160 through line 28 to reach the first reboiler 112 (FIGS. 1-4). The amount of heat applied to the liquid stream by the first reboiler 112 can be increased to separate more methane from contaminants. The more heat applied by the reboiler 112 to the stream, the more methane separated from the liquid contaminants, though more contaminants will also be vaporized.

The first reboiler 112 may also apply heat to the stream within the distillation tower 104, 204. Specifically, the heat applied by the first reboiler 112 warms up the lower section 106. This heat travels up the lower section 106 and supplies heat to warm solids entering a melt tray assembly 139 (FIGS. 1-4) of the middle controlled freeze zone section 108 so that the solids form a liquid and/or slurry mix.

The second reboiler 172 applies heat to the stream within the lower section 106. This heat is applied closer to the middle controlled freeze zone section 108 than the heat applied by the first reboiler 112. As a result, the heat applied by the second reboiler 172 reaches the middle controlled freeze zone section 108 faster than the heat applied by the first reboiler 112. The second reboiler 172 also helps with energy integration.

The equipment may include a chimney assembly 135 (FIGS. 1-4). While falling to the bottom of the lower section 106, the liquid stream may encounter one or more of the chimney assemblies 135.

Each chimney assembly 135 includes a chimney tray 131 that collects the liquid stream within the lower section 106. The liquid stream that collects on the chimney tray 131 may be fed to the second reboiler 172. After the liquid stream is heated in the second reboiler 172, the stream may return to the middle controlled freeze zone section 106 to supply heat to the middle controlled freeze zone section 106 and/or the melt tray assembly 139. Unvaporized stream exiting the second reboiler 172 may be fed back to the distillation tower 104, 204 below the chimney tray 131. Vapor stream exiting the second reboiler 172 may be routed under or above the chimney tray 131 when the vapor stream enters the distillation tower 104, 204.

The chimney tray 131 may include one or more chimneys 137. The chimney 137 serves as a channel that the vapor stream in the lower section 106 traverses. The vapor stream travels through an opening in the chimney tray 131 at the bottom of the chimney 137 to the top of the chimney 137. The opening is closer to the bottom of the lower section 106 than it is to the bottom of the middle controlled freeze zone section 108. The top is closer to the bottom of the middle controlled freeze zone section 108 than it is to the bottom of the lower section 106.

Each chimney 137 has attached to it a chimney cap 133. The chimney cap 133 covers a chimney top opening 138 of the chimney 137. The chimney cap 133 prevents the liquid stream from entering the chimney 137. The vapor stream exits the chimney assembly 135 via the chimney top opening 138.

After falling to the bottom of the lower section 106, the liquid stream exits the distillation tower 104, 204 through the liquid outlet 160. The liquid outlet 160 is within the lower section 106 (FIGS. 1-4). The liquid outlet 160 may be located at the bottom of the lower section 106.

After exiting through the liquid outlet 160, the feed stream may travel via line 28 to the first reboiler 112. The feed stream may be heated by the first reboiler 112 and vapor may then re-enter the lower section 106 through line 30. Unvaporized liquid may continue out of the distillation process via line 24.

The system may include an expander device 114 (FIGS. 1-4). After entering line 24, the heated liquid stream may be expanded in the expander device 114. The expander device 114 may be any suitable device, such as a valve. The valve 114 may be any suitable valve, such as a J-T valve.

The system may include a heat exchanger 116 (FIGS. 1-4). The liquid stream heated by the first reboiler 112 may be cooled or heated by the heat exchanger 116. The heat exchanger 116 may be a direct heat exchanger or an indirect heat exchanger. The heat exchanger 116 may comprise any suitable heat exchanger.

The vapor stream in the lower section 106 rises from the lower section 106 to the middle controlled freeze zone section 108. The middle controlled freeze zone section 108 is constructed and arranged to separate the feed stream 10 introduced into the middle controlled freeze zone section, or into the top of lower section 106, into a solid and a vapor stream. The middle controlled freeze zone section 108 operates at a temperature and pressure at which the feed stream forms a solid in the controlled freeze zone section, 301 (FIG. 1). The contaminant in the feed stream includes a first contaminant. The solid may be comprised more of contaminants than of methane. The vapor stream (i.e., methane-enriched vapor stream) formed may comprise more methane than contaminants.

The middle controlled freeze zone section 108 includes a lower section 40 and an upper section 39 (FIG. 5). The lower section 40 is below the upper section 39. The lower section 40 directly abuts the upper section 39. The lower section 40 is primarily but not exclusively a heating section of the middle controlled freeze zone section 108. The upper section 39 is primarily but not exclusively a cooling section of the middle controlled freeze zone section 108. The temperature and pressure of the upper section 39 are chosen so that the solid can form in the middle controlled freeze zone section 108.

The middle controlled freeze zone section 108 may comprise a melt tray assembly 139 that is maintained in the middle controlled freeze zone section 108, 302 (FIGS. 1-5). The melt tray assembly 139 is within the lower section 40 of the middle controlled freeze zone section 108. The melt tray assembly 139 is not within the upper section 39 of the middle controlled freeze zone section 108.

The melt tray assembly 139 is constructed and arranged to melt solids formed in the middle controlled freeze zone section 108. When the warm vapor stream rises from the lower section 106 to the middle controlled freeze zone section 108, the vapor stream immediately encounters the melt tray assembly 139 and supplies heat to melt the solid. The melt tray assembly 139 may comprise at least one of a melt tray 118, a bubble cap 132, a liquid 130 and heat mechanism(s) 134.

The melt tray 118 may collect a liquid and/or slurry mix. The melt tray 118 divides at least a portion of the middle controlled freeze zone section 108 from the lower section 106. The melt tray 118 is at the bottom 45 of the middle controlled freeze zone section 108.

One or more bubble caps 132 may act as a channel for the vapor stream rising from the lower section 106 to the middle controlled freeze zone section 108. The bubble cap 132 may provide a path for the vapor stream up the riser 140 and then down and around the riser 140 to the melt tray 118. The riser 140 is covered by a cap 141. The cap 141 prevents the liquid 130 from travelling into the riser and it also helps prevent solids from travelling into the riser 140. The vapor stream's traversal through the bubble cap 132 allows the vapor stream to transfer heat to the liquid 130 within the melt tray assembly 139.

One or more heat mechanisms 134 may further heat up the liquid 130 to facilitate melting of the solids into a liquid and/or slurry mix. The heat mechanism(s) 134 may be located anywhere within the melt tray assembly 139. For example, as shown in FIGS. 1-4, a heat mechanism 134 may be located around bubble caps 132. The heat mechanism 134 may be any suitable mechanism, such as a heat coil. The heat source of the heat mechanism 134 may be any suitable heat source.

The liquid 130 in the melt tray assembly is heated by the vapor stream. The liquid 130 may also be heated by the one or more heat mechanisms 134. The liquid 130 helps melt the solids formed in the middle controlled freeze zone section 108 into a liquid and/or slurry mix. Specifically, the heat transferred by the vapor stream heats up the liquid, thereby enabling the heat to melt the solids. The liquid 130 is at a level sufficient to melt the solids.

The middle controlled freeze zone section 108 may also comprise a spray assembly 129. The spray assembly 129 cools the vapor stream that rises from the lower section 40. The spray assembly 129 sprays liquid, which is cooler than the vapor stream, on the vapor stream to cool the vapor stream. The spray assembly 129 is within the upper section 39. The spray assembly 129 is not within the lower section 40. The spray assembly 129 is above the melt tray assembly 139. In other words, the melt tray assembly 139 is below the spray assembly 129.

The spray assembly 129 includes one or more spray nozzles 120 (FIGS. 1-4). Each spray nozzle 120 sprays liquid on the vapor stream. The spray assembly 129 may also include a spray pump 128 (FIGS. 1-4) that pumps the liquid. Instead of a spray pump 128, gravity may induce flow in the liquid.

The liquid sprayed by the spray assembly 129 contacts the vapor stream at a temperature and pressure at which solids form. Solids, containing mainly contaminants, form when the sprayed liquid contacts the vapor stream. The solids fall toward the melt tray assembly 139.

The temperature in the middle controlled freeze zone section 108 cools down as the vapor stream travels from the bottom of the middle controlled freeze zone section 108 to the top of the middle controlled freeze zone section 108. The methane in the vapor stream rises from the middle controlled freeze zone section 108 to the upper section 110. Some contaminants may remain in the methane and also rise. The contaminants in the vapor stream tend to condense or solidify with the colder temperatures and fall to the bottom of the middle controlled freeze zone section 108.

The solids form the liquid and/or slurry mix when in the liquid 130. The liquid and/or slurry mix flows from the middle controlled freeze zone section 108 to the lower distillation section 106. The liquid and/or slurry mix flows from the bottom of the middle controlled freeze zone section 108 to the top of the lower section 106 via a line 22 (FIGS. 1-4). The line 22 may be an exterior line. The line 22 may extend from the distillation tower 104, 204. The line 22 may extend from the middle controlled freeze zone section 108. The line may extend to the lower section 106. The line 22 may extend from an outer surface of the distillation tower 104, 204.

The vapor stream that rises in the middle controlled freeze zone section 108 and does not form solids or otherwise fall to the bottom of the middle controlled freeze zone section 108, rises to the upper section 110. The upper section 110 operates at a temperature and pressure and contaminant concentration at which no solid forms. The upper section 110 is constructed and arranged to cool the vapor stream to separate the methane from the contaminants. Reflux in the upper section 110 cools the vapor stream. The reflux is introduced into the upper section 110 via line 18. Line 18 may extend to the upper section 110. Line 18 may extend from an outer surface of the distillation tower 104, 204.

After contacting the reflux in the upper section 110, the feed stream forms a vapor stream and a liquid stream. The vapor stream mainly comprises methane. The liquid stream comprises relatively more contaminants. The vapor stream rises in the upper section 110 and the liquid falls to a bottom of the upper section 110.

To facilitate separation of the methane from the contaminants when the stream contacts the reflux, the upper section 110 may include one or more mass transfer devices 176. Each mass transfer device 176 helps separate the methane from the contaminants. Each mass transfer device 176 may comprise any suitable separation device, such as a tray with perforations, or a section of random or structured packing to facilitate contact of the vapor and liquid phases.

After rising, the vapor stream may exit the distillation tower 104, 204 through line 14. The line 14 may emanate from an upper part of the upper section 110. The line 14 may extend from an outer surface of the upper section 110.

From line 14, the vapor stream may enter a condenser 122. The condenser 122 cools the vapor stream to form a cooled stream. The condenser 122 at least partially condenses the stream.

From line 14, the vapor stream may enter a condenser 122 of the system. The condenser 122 cools the vapor stream to form a cooled stream. The condenser 122 at least partially condenses the stream.

After exiting the condenser 122, the cooled stream may enter a separator 124 of the system. The separator 124 separates the vapor stream into liquid and vapor streams. The separator may be any suitable separator that can separate a stream into liquid and vapor streams, such as a reflux drum.

Once separated, the vapor stream may exit the separator 124 as sales product. The sales product may travel through line 16 for subsequent sale to a pipeline and/or condensation to be liquefied natural gas.

Once separated, the liquid stream may return to the upper section 110 through line 18 as the reflux. The reflux may travel to the upper section 110 via any suitable mechanism, such as a reflux pump 150 (FIGS. 1 and 3) or gravity (FIGS. 2 and 4).

The liquid stream (i.e., freezing zone liquid stream) that falls to the bottom of the upper section 110 collects at the bottom of the upper section 110. The liquid may collect on tray 183 (FIGS. 1 and 3) or at the bottommost portion of the upper section 110 (FIGS. 2 and 4). The collected liquid may exit the distillation tower 104, 204 through line 20 (FIGS. 1 and 3) or outlet 260 (FIGS. 2 and 4). The line 20 may emanate from the upper section 110. The line 20 may emanate from a bottom end of the upper section 110. The line 20 may extend from an outer surface of the upper section 110.

The line 20 and/or outlet 260 connect to a line 41. The line 41 leads to the spray assembly 129 in the middle controlled freeze zone section 108. The line 41 emanates from the holding vessel 126. The line 41 may extend to an outer surface of the middle controlled freeze zone section 110.

The line 20 and/or outlet 260 may directly or indirectly (FIGS. 1-4) connect to the line 41. When the line 20 and/or outlet 260 directly connect to the line 41, the liquid spray may be sent to the spray nozzle(s) 120 via any suitable mechanism, such as the spray pump 128 or gravity. When the line 20 and/or outlet 260 indirectly connect to the line 41, the lines 20, 41 and/or outlet 260 and line 41 may directly connect to a holding vessel 126 (FIGS. 1 and 3). The holding vessel 126 may house at least some of the liquid spray before it is sprayed by the nozzle(s). The liquid spray may be sent from the holding vessel 126 to the spray nozzle(s) 120 via any suitable mechanism, such as the spray pump 128 (FIGS. 1-4) or gravity. The holding vessel 126 may be needed when there is not a sufficient amount of liquid stream at the bottom of the upper section 110 to feed the spray nozzles 120.

To help prevent accumulation of solid in the middle controlled freeze zone section 108, the liquid 130 in the middle controlled freeze zone section 108 should be at, at least a predetermined liquid level. The predetermined level is a level of liquid that is sufficient to melt the solid by the end of start-up. The start-up is the period of time that the system must run to establish a normal temperature and/or composition profile within the distillation tower 104, 204 and/or to establish a normal mass flow into and out of the distillation tower, 104, 204.

Additional processing may need to occur during start-up of the distillation tower 104, 204 to ensure that the liquid level is at least at the predetermined liquid level by the end of start-up. The additional processing may need to occur if the feed stream entering the distillation tower 104, 204 during start-up contains less than 20% contaminant. If the feed stream entering the distillation tower 104, 204 during start-up contains less than 20% contaminant, solids may accumulate in the middle controlled freeze zone section 108. For example, solids may accumulate on the melt tray 118 without melting to form liquid. Solids may accumulate because the feed stream entering the distillation tower 104, 204 does not contain enough contaminant to yield sufficient melt tray liquid in the early stages of operation while starting up the unit. This accumulation of solids may disrupt the entire process of separating the feed stream after start-up. While the additional processing may not need to occur if the feed stream contains more than 20% contaminant, the additional processing can still occur.

The additional processing may include introducing the feed stream 10 to the middle controlled freeze zone section 108 during start-up, 303 (FIG. 6). The feed stream 10 may be directly introduced to the distillation tower 104, 204 via the middle controlled freeze zone section 108. The feed stream 10 may be introduced into the middle controlled freeze zone section 108 via any suitable mechanism. For example, the feed stream 10 may be introduced into the middle controlled freeze zone section 108 in the manner described in the application entitled “Method and System for Separating a Feed Stream with a Feed Distribution Mechanism” by Jaime Valencia and filed on the same day as the instant application. After the feed stream 10 is introduced into the middle controlled freeze zone section 108, liquid may be sprayed on the feed stream 10 by the spray assembly 129 to help separate the contaminant in the feed stream from the methane in the feed stream by forming the solid. The contaminant may comprise a first contaminant. Solid that falls to the bottom of the middle controlled freeze zone section 108 may melt, because of heat applied by the heating mechanism 134, first reboiler 112, second reboiler 172, and/or vapor stream rising from the lower section 106, thereby becoming part of the liquid in the melt tray assembly 139. The liquid that becomes part of the liquid in the melt tray assembly 139 helps accumulate the liquid in the melt tray assembly 139 until the liquid is at least at the predetermined liquid level, 304 (FIG. 6).

To prevent the solid from accumulating, the additional process may also include feeding a second contaminant to the middle controlled freeze zone section 108, 305 (FIG. 6). After the second contaminant is fed to the middle controlled freeze zone section 108, the second contaminant may be added to the melt tray assembly 139, 306 (FIG. 6) as part of the liquid. The feeding and adding of the second contaminant helps accumulate the liquid in the melt tray assembly 139 (FIG. 6) until the liquid is at least at a predetermined liquid level in the middle controlled freeze zone section 108. The predetermined liquid level is the level needed to prevent accumulation of the solid in the middle controlled freeze zone section 108 during start-up.

The second contaminant may be continuously or intermittently fed to the melt tray assembly 139. The second contaminant may be continuously or intermittently fed to ensure that the liquid level is at least at the predetermined liquid level at the end of start-up. During start-up, some of the liquid in the melt tray assembly 139 may turn into vapor and/or be sent to the stripper section 106, thereby lowering the liquid level in the melt tray assembly 139. The lowering of the liquid level may cause a liquid level that was once at least equal to the predetermined liquid level to be less than the predetermined liquid level. When a liquid level once at least equal to the predetermined liquid level is less than the predetermined liquid level before the end of start-up, the second contaminant may continue to be intermittently or continuously fed to the melt tray assembly 139 during start-up. At times the second contaminant may be fed intermittently and at other times the second contaminant may be fed continuously in the same distillation tower.

Any suitable mechanism may be used to determine that the liquid level is less than the predetermined liquid level. For example, at least one of the underflow and overflow weirs, and the liquid level indicators described in the application entitled “A Method and System of Maintaining a Liquid Level in a Distillation Tower” by Jaime Valencia et al. and filed on the same day as the instant application may be used to determine whether the liquid is less than the predetermined liquid level.

The second contaminant may be continuously or intermittently fed to the middle controlled freeze zone section from at least one of a first storage unit 318 and an indirect channel 127, 145, 147 (FIG. 5).

The first storage unit 318 holds the second contaminant. The first storage unit 318 may be any suitable storage unit. The second contaminant in the first storage unit 318 may be directly fed to the melt tray assembly 139. The first storage unit 318 may connect to a line 119 that connects to the melt tray assembly 139. The line 119 may extend from the portion of the middle controlled freeze zone section 108 that includes the melt tray assembly 139 to the first storage unit 318. The line 119 may be referred to as a first channel. The second contaminant from the first storage unit 318 may be fed to the middle tray assembly 139 before and/or after the feed stream is fed to the middle controlled freeze zone section 108.

The second contaminant from the first storage unit 318 may be any suitable contaminant For example, the second contaminant may comprise carbon dioxide. The carbon dioxide may be liquid carbon dioxide. The second contaminant may comprise at least one the same type of contaminant as the first contaminant and a different type of contaminant as the first contaminant.

The indirect channel 127, 145, 147 transports the second contaminant to the line 12, 119. Because the indirect channel 127, 145, 147 transports the second contaminant to the line 12, 119 before the second contaminant enters the middle controlled freeze zone section 108, the second contaminant is indirectly fed to the melt tray assembly 139 when the second contaminant is fed to the middle controlled freeze zone section 108. The second contaminant may be directly fed above the melt tray assembly 139 when the second contaminant is fed to the middle controlled freeze zone section 108. The second contaminant may be directly fed into the melt tray assembly 139 when the second contaminant is fed to the middle controlled freeze zone section 108.

When the indirect channel 127, 145 transports the second contaminant, the second contaminant may be mixed with the feed stream before the feed stream is introduced to the middle controlled freeze zone section 108. This is so the second contaminant is mixed with the feed stream outside of the distillation tower 108.

When the indirect channel 147 transports the second contaminant, the second contaminant may not be mixed with the feed stream before the feed stream is introduced to the middle controlled freeze zone section 108.

The indirect channel 127, 145, 147 extends from at least one of (i) the distillation tower 104, 204 to the inlet channel 12, (ii) the distillation tower 104, 204 to the first channel 119 and (iii) a second storage unit 146 to the inlet channel 12. The indirect channel 127 may be referred to as the first indirect channel. The indirect channel 145 may be referred to as the second indirect channel. The indirect channel 147 may be referred to as the third indirect channel. The first storage unit 318 and the second storage unit 146 could be one and the same.

When the first indirect channel 127 extends from the distillation tower 104, 204 to the inlet channel 12, the first indirect channel 127 extends from the lower section 106. The first indirect channel 127 may extend from the bottom of the lower section 106. For example, the first indirect channel 127 may extend from the liquid outlet 160 of the lower section 106. The first indirect channel 127 may indirectly extend from the liquid outlet 160. For example, the first indirect channel 127 may extend from line 28 and/or line 24. The first indirect channel 127 transports the liquid stream (e.g., enriched contaminant bottom liquid stream) that exits the lower section 106 via the liquid outlet 160.

When the third indirect channel 147 extends from the distillation tower 104, 204 to the first channel 119, the third indirect channel 147 extends from the lower section 106. The third indirect channel 147 may extend from the bottom of the lower section 106. For example, the third indirect channel 147 may extend from the liquid outlet 160 of the lower section 106. The third indirect channel 147 may indirectly extend from the liquid outlet 160. For example, the third indirect channel 147 may extend from line 28 and/or line 24. The third indirect channel 147 transports the liquid stream (e.g. enriched contaminant bottom liquid stream) that exits the lower section 106 via the outlet 160. The third indirect channel 147 may feed the second contaminant to the first channel 119 in the absence of feeding the second contaminant to the feed stream. In other words, the third indirect channel 147 may feed the second contaminant to the first channel 119 without the third indirect channel 147 connecting to the inlet channel 12 such that the third indirect channel 147 connects to the first channel 119 but not the inlet channel 12.

The second contaminant in the indirect channel 145, 147 may comprise the same type of contaminant as the first contaminant. This second contaminant includes the first contaminant because the second contaminant is the first contaminant processed in the middle controlled freeze zone section 108 and the lower section 106.

When the second indirect channel 145 extends from the second storage unit 146 to the inlet channel 12, the second storage unit 146 holds the second contaminant. The second storage unit 146 may be any suitable storage unit.

The second contaminant from the second storage unit 146 may be any suitable contaminant. For example, the second contaminant may comprise at least one of carbon dioxide and an anti-freeze solution. The anti-freeze solution may comprise at least one of ethane, methanol, propane, butane, light olefins (e.g. ethylene), light ethers (e.g. dimethyl ether), acetylene, and hydrogen sulfide. Other examples of anti-freeze solution are also contemplated. The second contaminant may comprise at least one the same type of contaminant as the first contaminant and a different type of contaminant as the first contaminant

While the second contaminant is generally discussed above as only being fed to the middle controlled freeze zone section 108 during start-up, the second contaminant may also be fed after start-up. The second contaminant may be fed after start-up if, for example, the liquid level becomes lower than the predetermined liquid level.

The second contaminant may be fed to the middle controlled freeze zone section 108 at least one of before and after introducing the feed stream into the middle controlled freeze zone section 108. For example, the second contaminant may be fed to the middle controlled freeze zone section 108 when feed stream is first fed to the middle controlled freeze zone section 108 and/or not initially fed until after feed stream is first fed to the middle controlled freeze zone section 108.

It is important to note that the steps depicted in FIG. 6 are provided for illustrative purposes only and a particular step may not be required to perform the inventive methodology. The claims, and only the claims, define the inventive system and methodology.

Disclosed aspects may be used in hydrocarbon management activities. As used herein, “hydrocarbon management” or “managing hydrocarbons” includes hydrocarbon extraction, hydrocarbon production, hydrocarbon exploration, identifying potential hydrocarbon resources, identifying well locations, determining well injection and/or extraction rates, identifying reservoir connectivity, acquiring, disposing of and/or abandoning hydrocarbon resources, reviewing prior hydrocarbon management decisions, and any other hydrocarbon-related acts or activities. The term “hydrocarbon management” is also used for the injection or storage of hydrocarbons or CO₂, for example the sequestration of CO₂, such as reservoir evaluation, development planning, and reservoir management. The disclosed methodologies and techniques may be used to produce hydrocarbons in a feed stream extracted from, for example, a subsurface region. The feed stream extracted may be processed in the distillation tower 104, 204 and separated into hydrocarbons and contaminants The separated hydrocarbons exit the middle controlled freeze zone section 108 or the upper section 110 of the distillation tower. Some or all of the hydrocarbons that exit are produced, 307. Hydrocarbon extraction may be conducted to remove the feed stream from for example, the subsurface region, which may be accomplished by drilling an oil well using oil drilling equipment. The equipment and techniques used to drill a well and/or extract the hydrocarbons are well known by those skilled in the relevant art. Other hydrocarbon extraction activities and, more generally, other hydrocarbon management activities, may be performed according to known principles.

As utilized, the terms “approximately,” “about,” “substantially,” and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numeral ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and are considered to be within the scope of the disclosure.

It should be understood that numerous changes, modifications, and alternatives to the preceding disclosure can be made without departing from the scope of the disclosure. The preceding description, therefore, is not meant to limit the scope of the disclosure. Rather, the scope of the disclosure is to be determined only by the appended claims and their equivalents. It is also contemplated that structures and features in the present examples can be altered, rearranged, substituted, deleted, duplicated, combined, or added to each other.

The articles “the”, “a” and “an” are not necessarily limited to mean only one, but rather are inclusive and open ended so as to include, optionally, multiple such elements. 

What is claimed is:
 1. A method for separating a feed stream in a distillation tower, the method comprising: providing a controlled freeze zone section in the distillation tower, wherein the controlled freeze zone section comprises a melt tray assembly and a spray assembly and wherein the spray assembly is above the melt tray assembly; introducing the feed stream to the controlled freeze zone section, wherein the feed stream comprises a first contaminant; spraying a liquid from the spray assembly onto the feed stream in the controlled freeze zone section of the distillation tower; operating the controlled freeze zone section of the distillation tower at a temperature and pressure at which the first contaminant in the feed stream forms a solid in the controlled freeze zone section; and feeding a liquid comprising a second contaminant to the melt tray assembly above the melt tray in the controlled freeze zone section of the distillation tower; wherein the liquid comprising the second contaminant is fed into the controlled freeze zone section until the liquid accumulated in the melt tray assembly is at a predetermined level in the controlled freeze zone section; and wherein the feeding of the second contaminant only occurs while starting up the distillation tower.
 2. The method of claim 1, wherein feeding the second contaminant occurs before introducing the feed stream.
 3. The method of claim 1, wherein feeding the second contaminant comprises directly feeding the second contaminant to the controlled freeze zone section.
 4. The method of claim 3, wherein directly feeding the second contaminant occurs one of continuously and intermittently.
 5. The method of claim 1, wherein the second contaminant comprises the same contaminant as the first contaminant.
 6. The method of claim 1, wherein the first contaminant comprises the same contaminant as the second contaminant.
 7. The method of claim 1, wherein each of the first contaminant and the second contaminant comprise carbon dioxide.
 8. The method of claim 1, further comprising recovering hydrocarbons from the feed stream.
 9. The method of claim 1, wherein feeding the second contaminant occurs after introducing the feed stream.
 10. The method of claim 1, wherein feeding the second contaminant comprises indirectly feeding the second contaminant to the controlled freeze zone section.
 11. The method of claim 10, wherein indirectly feeding the second contaminant occurs one of continuously and intermittently.
 12. The method of claim 10, wherein indirectly feeding the second contaminant comprises at least one of (i) feeding the second contaminant before introducing the feed stream to the controlled freeze zone section and (ii) feeding the second contaminant to a first channel in the absence of feeding the second contaminant to the feed stream.
 13. The method of claim 12, wherein (i) comprises mixing the second contaminant with the feed stream before introducing the feed stream to the controlled freeze zone section.
 14. The method of claim 1, wherein the first contaminant comprises carbon dioxide. 